Piping stick systems

ABSTRACT

The piping stick can define a sealable volume including a plurality of piping sections and a plurality of control sections. The non-connected end of the piping sections of the piping stick can be capped. The piping stick can be assembled by assembling the plurality of control sections and the plurality of piping sections, pressurizing the piping stick at a first time and determining the integrity of the piping stick by evaluating the pressure in the piping stick at a second time.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/797,941 filed Mar. 12, 2013, now U.S. Pat. No. 9,222,862. The entirecontents of each of these applications and their priority filings areincorporated herein by reference for all purposes.

BACKGROUND OF THE INVENTION

Embodiments of the present invention relate to integrated heating,ventilation, and air conditioning (HVAC) systems and methods, and inparticular to approaches that include embedded coils and other heatexchangers.

In general, HVAC systems control the temperature and humidity of indoorair. In most HVAC systems, air is drawn in, filtered, cooled anddehumidified or heated and humidified, and then delivered to an airconditioned space. The greatest portion of incoming air is drawn fromthe air conditioned space for recirculation through the HVAC system.HVAC system includes fans and ductwork for moving conditioned air towhere it is needed while passing it through cooling and/or a heatingsections of the ductwork.

HVAC systems in residential, commercial, education and researchbuildings usually include metallic pipes, hollow composite materialssuch as tubes, and the like. The systems are typically supported fromand between floor or ceiling joists. The HVAC system typically includesa primary or main duct. A series of smaller branch ducts which extendfrom the main duct are mounted between adjacent floor or ceiling joists.Such main and branch ducts are normally supported by metal hangerslocated between the joists. Often the branch ducts include pipes andconduit lines for transporting liquid or gas which are suspended fromceiling joists or an adjacent wall typically with Unistrut®, threadedrod, couplings, and various hanger brackets.

Piping and conduits that supply gas and/or liquids within buildingsbenefit from careful preparation. Builders or contractors typically useladders or scaffolding to reach areas where piping is routed soinstallation may be cumbersome. Occasionally the pipe or conduits areprepared on the ground and installed by ladder as more completeassemblies. Pipe and conduit assemblies prepared on the ground or afloor of a building under construction are more unwieldy than theunassembled components, but pre-assembly is often more practical.Furthermore, conditions existing at construction sites and the number ofdiffering types of components used in assembling a HVAC system rendercataloging known HVAC components a challenge.

Generically, a terminal unit, also sometimes referred to as an airhandling unit, is a HVAC system component that is located near an airconditioned space that regulates the temperature and/or volume of airsupplied to the space. When providing air to a more critical environmentsuch as a laboratory, an almost identical ductwork section is frequentlyreferred to as a lab valve damper rather than as a terminal unit, withthe distinction generally relating to the precision with which the unitcontrols the temperature and humidity of conditioned air. As usedthroughout this document, the phrase terminal unit encompasses either aterminal unit or a lab valve damper.

A HVAC system may be assembled using anyone of several different typesof terminal units. Generally, the mechanical portion of a terminal unitincludes a casing through which air flows during operation of a HVACsystem. Accordingly, the casing includes an inlet for receiving air fromductwork of a HVAC system, and an outlet for supplying air to a space ina building. Casings are usually fabricated from 22 gauge galvanizedsheet steel. Due to the use of such light material, casings are easilydamaged during shipping to a building site and during installation intothe HVAC system. Those familiar with such damage to terminal unitcasings frequently refer to it as “oil canning” because it resembles howa light gauge oil can collapses as the liquid flows out.

In a typical hydronic (all-water) HVAC system, the mechanical portion ofa terminal unit includes a heat exchanging coil. Heated and/or cooledwater is pumped from a central plant through pipes to the coil. Air fromthe HVAC system's ductwork passes through the coil after entering andbefore leaving the casing. Usually, a single terminal unit is dedicatedfor heating and/or cooling each air conditioned space. Air from the ductconnected to the terminal unit passes through the coil to be heatedand/or cooled by water flowing through the coil before the air entersthe air conditioned space.

A Variable Air Volume (“VAV”) HVAC system, in response to a controlsignal from a thermostat or room sensor, supplies only that volume ofhot and/or cold air to an air conditioned space needed to satisfy thespace's thermal load, A VAV HVAC system, meets changing cooling and/orheating requirements by adjusting the amount, rather than thetemperature, of air that flows to a space. For most buildings, a VAVHVAC system yields the best combination of comfort, first cost, and lifecycle cost.

A VAV terminal unit is a relatively complex assembly which includessheet metal, plumbing, electrical and pneumatic components. For example,a VAV terminal unit includes an airflow sensor that senses the velocityof air entering the terminal unit. To adjust the volume of cold air, aVAV terminal unit frequently includes a damper which automatically opensand closes as needed.

As a thermal load of a space decreases, the damper starts closingthereby reducing the amount of heated or cooled air supplied to thespace. Alternatively, the volume of air entering a space may becontrolled by varying the speed of a fan included in the terminal unit.For either type of VAV terminal unit, VAV HVAC systems save energyconsumed by fans in comparison with alternative HVAC systems bycontinually adjusting airflow to the heating and/or cooling required.

To be operable and fully-functional, terminal units for a hydronic HVACsystem often include a coil, ductwork for supplying air to the coil andreceiving air from the coil, plumbing for supplying water into andreceiving water from the coil, and a control valve for regulating theamount of water flowing through the coil.

To match the flow of air through the terminal unit's ductwork to theprofile of the coil, the terminal unit's ductwork may include transitionsections both for air entering the coil and for air leaving the coil. Inaddition, a terminal unit may also include a re-heat coil, and/or asound attenuator. In a terminal unit adapted for use in a VAV HVACsystem, the terminal unit's ductwork may also include a damper and adamper actuator or variable speed fan for controlling the volume of airsupplied by the terminal unit, and an airflow sensor for sensing thevolume of air passing through the terminal unit.

Usually, all of the various parts needed to assemble a fully-functionalVAV HVAC system's terminal unit arrive at building construction sites asseparate components. Generally, these components are then assembled intoa fully functional terminal unit at the construction site. Due tocluttered working conditions usually existing at a construction sitewhere workers skilled in different crafts, e.g. plumbing, electrical,structural, etc., must concurrently collaborate to complete the buildingproject, assembling the various components into a fully functionalterminal unit may occupy the better part of a day. Furthermore, presentpractices and equipment are poorly adapted for swiftly constructing ahigh quality HVAC system that is easily commissioned.

For example, because it is less expensive to wire a HVAC system'sterminal units with 24 volt low voltage electrical power rather than 220or 110 volt power, presently sections of buildings include transformertrees which an electrician generally assembles by installing multiplestep down transformers on an electrical panel. This technique permitswiring 220 or 110 volt electrical power to the transformer tree on eachpanel, with the 24 volt low voltage electrical power then being wiredindividually from a transformer on the panel over distances of five (5)to one hundred (100) feet to a terminal units for energizing its DirectDigital Control (“DDC”) controller, and 2 way or 3 way automatictemperature control (“ATC”) control valve.

Usually, terminal units are supported from a building using anglebrackets, straps, or thread rod. Usually these support devices areattached directly to the terminal unit. Terminal unit casings areusually made using 22 gauge sheet metal. Due to the use of this lightmaterial, casings are easily dented or bent during installation.

With current construction site labor costing up to $80.00/hour or more,assembling a terminal unit at a construction site may cost $500.00 to$1,000.00 for labor alone. Furthermore, terminal units assembled at aconstruction site generally differ from one another due to assembly bydifferent craftsmen, and insufficient use of identical components inassembling each terminal unit. Due to conditions existing atconstruction sites and the number of differing types of components usedin assembling a HVAC system, cataloging the components used inassembling the system is impractical. Lastly, construction sitesgenerally lack any facilities for individually pre-testing buildingcomponents, such as terminal units, assembled on-site.

After assembling a HVAC system, it should be activated, tested andcommissioned to ensure IAQ). Testing a HVAC system only after it iscompletely assembled inevitably results in many hours of problem-solvingand leak-hunting. Usually, there are leaky joints, broken valves,damaged pipes, leaky coils and improperly assembled components that mustbe tracked down which further increases building costs. After finding afaulty component, it must be identified, ordered and replaced whichtakes time and delays completion of the building project. Furthermore,years after a building project is complete to maintain IAQ a buildingmanager responsible for the HVAC system's maintenance will often have toidentify and replace broken components.

The preceding considerations arising from construction site assembly offully functional terminal units slows construction, increase buildingcosts, requires rework when a terminal unit experiences an initialfailure, and ultimately makes more difficult and expensive maintaining abuilding's HVAC system years after those responsible for its assemblyare no longer available.

Current techniques for implementing HVAC systems often requiredancillary components such as flow controls, ATC valves, and the like tobe added to HVAC piping structures in the field or at a jobsiteconstruction location. Relatedly, such ancillary components, pipingstructures, and the like may be susceptible to damage during transport.What is needed are improved HVAC systems and methods that allow HVACcomponents to be configured prior to shipping, and be shipped withoutrisk of damage. Embodiments of the present invention provide solutionsfor at least some of these needs.

BRIEF SUMMARY OF THE INVENTION

In one embodiment, the present disclosure provides a method ofmanufacturing an HVAC system. The method includes obtaining a pipingstick that has a first tubular end section, a second tubular endsection, a sealed and pressurized interior lumen defined at least inpart by the first and second tubular end sections, a pressure gauge influid communication with the interior lumen and indicating anon-atmospheric pressure therein, a first valve coupled with the firstend section, and a second valve coupled with the second end section,reading the pressure gauge to verify that the sealed interior lumen ofthe piping stick is pressurized to the non-atmospheric pressure, cuttingthe piping stick to create a first portion including the first valve andthe first tubular end section and a second portion including the secondvalve and the second tubular end section, and incorporating the firstand second portions into the HVAC system.

In some embodiments of the method of manufacturing an HVAC system, thefirst tubular end section can include a sealed end and a non-sealed endconnecting to the first valve. In some embodiments of the method ofmanufacturing an HVAC system, the method can include cutting the firsttubular end section between the sealed end and the non-sealed end so asto separate the sealed end from the first valve. In some embodiments ofthe method of manufacturing an HVAC system, the second tubular endsection can include a sealed end and a sealed end connecting to thefirst valve. In some embodiments, the method can include cutting thesecond tubular end section between the sealed end and the non-sealed endso as to separate the sealed end from the second valve.

In some embodiments of the method of manufacturing an HVAC system, thepiping stick can include an indicator of the location for cutting thepiping stick to create a first portion and a second portion, and in someembodiments of the method of manufacturing an HVAC system, cutting thepiping stick to create a first portion and a second portion can includecutting the piping stick at the indicated location.

In some embodiments of the method of manufacturing an HVAC system, thenon-atmospheric pressure can be a superatmospheric pressure, and in someembodiments of the method of manufacturing an HVAC system, thenon-atmospheric pressure can be a subatmospheric pressure. In someembodiments of the method of manufacturing an HVAC system, the firstvalve and the second valve are open.

In some embodiments the method of manufacturing an HVAC system includesreading the pressure gauge to verify the sealed interior lumen of thepiping stick is pressurized to the non-atmospheric pressure can verifythat the first tubular end section and the second tubular end sectionare pressurized to the non-atmospheric pressure.

In some embodiments of the method of manufacturing an HVAC system, thefirst control section comprises a single flow assembly that can be, forexample, an inlet piping section assembly, and the second controlsection comprises a single flow assembly that can be, for example, anoutlet piping section. In some embodiments of the method ofmanufacturing an HVAC system, the first control section can comprise aplurality of flow assemblies which can be, for example, a plurality ofinlet piping sections, a plurality of outlet piping sections, or aplurality of both inlet and outlet piping sections. In some embodimentsof the method of manufacturing an HVAC system, the second controlsection can comprise a plurality of flow assemblies which can be, forexample, a plurality of inlet piping sections, a plurality of outletpiping sections, or a plurality of both inlet and outlet pipingsections. In some embodiments in which one or both of the first and/orsecond control sections comprises a plurality of flow assemblies, theflow assemblies in the plurality of flow assemblies can be connected toeach other by piping sections.

In one embodiment, the present disclosure provides a method ofmanufacturing a piping stick. The method includes, connecting a firsthydronic unit to a first tubular end section and a tubular interiorsection, connecting a second hydronic unit to a second tubular endsection and the tubular interior section, the second hydronic unitincluding a pressure gauge, sealing a first end of the first tubular endsection and a first end of the second tubular end section, pressurizingthe tubular interior section to a non-atmospheric pressure, andvalidating the pressure of the tubular interior section.

In some embodiments, the method of manufacturing a piping stick includesadding an indicator of a location along the tubular interior section. Insome embodiments of the method of manufacturing a piping stick, theindicator of the location along the tubular interior section comprisesan adhered indicator. In some embodiments, the method of manufacturing apiping stick includes adding an indicator of a location along the firsttubular end section, and in some embodiments, the method ofmanufacturing a piping stick includes adding an indicator of a locationalong the second tubular end section. In some embodiments, the method ofmanufacturing a piping stick includes validating the pressure in thefirst tubular end section and the second tubular end section.

In one embodiment, the present disclosure provides a piping stick. Thepiping stick includes a first pipe having a first sealed end and asecond open end, a first control section attached to the second open endof the first pipe, a second pipe including a first open end attached tothe first control section and a second open end, a second controlsection attached to the second open end of the second pipe, and a thirdpipe having a first open end attached to the second control section anda second sealed end. In some embodiments, the piping stick ispressurized to a non-atmospheric pressure.

In some embodiments of the piping stick, the control section includes apressure gauge, and in some embodiments, the piping stick includes anindicator located along one of the first pipe, the second pipe, and thethird pipe, and indicating the location for the placement of a cut. Insome embodiments, the piping stick can include a first flow directionindicator associated with the first control section and a second flowdirection indicator associated with the second control section, and insome embodiments, the first flow direction indicator can bedistinguishable from the second flow direction indicator.

Further areas of applicability of the present disclosure will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating various embodiments, are intended for purposes ofillustration only and are not intended to necessarily limit the scope ofthe disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a piping stick according to oneembodiment of the present invention.

FIG. 1A is a perspective view of a two piece piping stick according toone embodiment of the present invention.

FIG. 2 is a perspective view of a fully-functional zone-control unitready for installation in a HVAC system, the zone-control unit includesa casing from which a pair of handles project that can receive and/orretain the piping stick, according to one embodiment of the presentinvention.

FIG. 3 is a perspective view of a fully-functional zone-control unitready for installation in a HVAC system, the zone-control unit includesa casing from which a pair of handles project, the handles include a cutout section for supporting the piping stick, according to one embodimentof the present invention.

FIG. 4 is a schematic illustration of a plurality of assembly portionscreated from a single piping stick, according to one embodiment of thepresent invention.

FIG. 4A is a perspective view of a fully-functional zone-control unitready for installation in a HVAC system, the zone-control unit includesa casing from which a pair of handles project, and control sectionsconnected to inlet and outlet assemblies.

FIG. 5 is a flowchart depicting one embodiment of a process for creatinga piping stick.

FIG. 6 is a flowchart depicting one embodiment of a process forassembling a piping stick, which process can be performed as part of theprocess for creating a piping stick depicted in FIG. 5.

FIG. 7 is a flowchart depicting one embodiment of a process forpressurizing a piping stick, which process can be performed as part ofthe process for creating a piping stick depicted in FIG. 5.

FIG. 8 is a flowchart depicting one embodiment of a process forvalidating a piping stick, which process can be performed as part of theprocess for creating a piping stick depicted in FIG. 5.

FIG. 9 is a flowchart illustrating one embodiment of a process forassembling an HVAC unit and/or a zone-control unit.

FIG. 10 is a flowchart illustrating one embodiment of a process forverifying a piping stick, which process can be performed as part of theprocess for assembling an HVAC unit and/or a zone-control unit asdepicted in FIG. 9.

FIG. 11 is a flowchart illustrating one embodiment of a process forcreating assembly portions from a piping stick, which process can beperformed as part of the process for assembling an HVAC unit and/or azone-control unit as depicted in FIG. 9.

FIG. 12 is a flowchart illustrating one embodiment of a process forcreating assembly portions by cutting a piping stick, which process canbe performed as part of the process for assembly and HVAC unit and/orzone-control unit as depicted in FIG. 9.

FIG. 13 is a flowchart illustrating one embodiment of a process forpreparing an HVAC unit and/or zone-control unit, which process can beperformed as part of the process for assembling an HVAC unit and/orzone-control unit as depicted in FIG. 9.

In the appended figures, similar components and/or features may have thesame reference label. Where the reference label is used in thespecification, the description is applicable to any one of the similarcomponents having the same reference label. Further, various componentsof the same type may be distinguished by following the reference labelby a dash and a second label that distinguishes among the similarcomponents. If only the first reference label is used in thespecification, the description is applicable to anyone of the similarcomponents having the same first reference label irrespective of thesecond reference label.

DETAILED DESCRIPTION OF THE INVENTION

The ensuing description provides preferred exemplary embodiment(s) only,and is not intended to limit the scope, applicability or configurationof the disclosure. Rather, the ensuing description of the preferredexemplary embodiment(s) will provide those skilled in the art with anenabling description for implementing a preferred exemplary embodiment.It is understood that various changes may be made in the function andarrangement of elements without departing from the spirit and scope asset forth in the appended claims.

Attached are pictures of various bracketing devices in addition tohandles that can be used with the piping stick, also referred to as theKoil Pak. The piping stick can ship in one piece with, or withoutbrackets installed for mounting on to sheetmetal duct/casing, or as anindividual set with brackets.

In describing the background, focus is on terminal units with hot waterre-heat. A person of skill in the art will recognize that the pipingstick can be used with any fluid coil/thermal transfer device includingthermal transfer devices configured to heating, cooling, and/or forsteam, In some embodiments, the fluid coil/thermal transfer device caninclude and/or be associated with, for example, fan coils, one orseveral air handling units (AHU), one or several chilled beams, one orseveral, water source, heat pumps, one or several radiant panels, one orseveral fin tubes, one or several convectors, etc.

The perspective view of FIG. 1 illustrates one embodiment of a pipingstick 100. The piping stick can be made from a variety of components,including, for example, components used in completing a zone-controlunit. The piping stick can include a plurality of control sections and aplurality of piping sections, and can define a sealable volumeincluding, for example, an interior lumen, including a seated interiorlumen.

The piping stick too depicted in the embodiment of FIG. 1 includes afirst control section 102 such as, for example, a first hydronic unit,and a second control section 104 such as, for example, a second hydronicunit. In some embodiments, for example, the control sections 102, 104can include components configured to allow a user and/or Contractor ofthe zone-control unit to control, adjust, and/or otherwise affect theoperation of the zone-control unit. In one embodiment, for example, andas depicted in FIG. 1, the first control section 102 can be an inletassembly, and the second control section 104 can be an outlet assembly,which inlet and outlet piping assemblies can be referred to as flowassemblies. In one embodiment, for example, the first control section102 can comprise plurality of flow assemblies, including, for example, aplurality of inlet piping assemblies, a plurality of outlet pipingassemblies, and/or a mixture of inlet and outlet piping assemblies. Inone embodiment, for example, the second control section 104 can compriseplurality of flow assemblies, including, for example, a plurality ofinlet piping assemblies, a plurality of outlet piping assemblies, and/ora mixture of inlet and outlet piping assemblies. In some embodiments inwhich one or both of the first and/or second control sections 102, 104comprise a plurality of flow assemblies, the plurality of flowassemblies can be connected to each other via a plurality of pipingsections in the same manner as the first control section 102 isconnected to the second control section 104 via a piping sectiondiscussed below.

As further seen in FIG. 4, the number of control sections 102, 104 inthe piping stick 100 can be represented by the integer N, In theembodiment depicted in FIG. 4, N=2. In some embodiments, N can be, forexample, 1, 3, 3, 4, 5, 6, 7, 8, 9, 10, 20, 50, 100, or any other orintermediate number. In some embodiments, the control sections 102, 104in a piping stick 100 can include any combination, permutation, orsequence of control sections 102, 104, of inlet and/or outlet pipingassemblies, and/or flow assemblies.

The piping stick 100 includes a first piping section 106, a secondpiping section 108, and a third piping section 110. The piping sections106, 108, 110 can mechanically and fluidly connect to the controlsections 102, 104 and connect the control sections 102, 104. In someembodiments, for example, the piping sections 106, 108, 110 can, inconnection with the control sections 1020 104 define and enclose avolume of the piping stick 100.

The piping sections 106, 108, 110 can be made of pipe that can have anydesired shape and/or dimensional properties. In some embodiments, forexample, the piping sections 106, 108, 110 can be tubular. In someembodiments, for example the piping sections 106, 108, 110 can be madefrom a variety of materials including, for example, a natural and/orman-made material including, for example, metal such as copper,aluminum, brass, steel, and/or iron, plastic, polymer, composite, or anyother desired material. In some embodiments, the shape and/ordimensional properties and material used in the construction of thepiping sections 106, 108, 110 can be based on the specific applicationin which the piping stick 100 will be used.

As seen in FIG. 1, the first piping section 106 includes a first endconnecting to the first control section 102 and a second end that isunconnected to another component of the piping stick 100. In someembodiments, for example, the second end of the first piping section 106can comprise a first cap 112. In some embodiments, for example, thefirst cap 112 can comprise a spun cap that can, for example, have athickness that is equal to, less than, and/or greater than the thicknessof the wall of the first piping section 106. In one embodiment, forexample, the first cap 112 can comprise a thickness that is five timesgreater than the thickness of the wall of the first piping section 106.The spun cap can comprise the same material and/or a different materialfrom that used in the other portions of the first piping section 106. Inone embodiment in which the first piping section 106 is made of copper,the spun cap can comprise a spun copper cap.

As further seen in FIG. 1 the second piping section 108 includes a firstend that is connected to the first control section 102 and a second endthat is connected to the second control section 104, and the thirdpiping section 110 includes a first end that is connected to the secondcontrol section 104 and a second end that is unconnected to anothercomponent of the piping stick 100. In some embodiments, for example, thesecond end of the third piping stick 110 can comprise a second cap 114.In some embodiments, for example, the second cap 114 can comprise a spuncap that can, for example, have a thickness that is equal to, less than,and/or greater than the thickness of the wall of the second pipingsection 108. In one embodiment, for example, the second cap 114 cancomprise a thickness that is five times greater than the thickness ofthe wall of the second piping section 108. The spun cap can comprise thesame material and/or a different material from that used in the otherportions of the first piping section 106. In one embodiment in which thesecond piping section 108 is made of copper, the spun cap can comprise aspun copper cap.

As seen in FIG. 1, the first end of the first piping section 106connects to the first control section 102 via a first union 116, In oneembodiment and as depicted in FIG. 1, a first portion of the first union116 engages with the first end of the first piping section 106 and thesecond portion of the first union 116 engages with a portion of a firstvalve 118. In one embodiment, for example, the first valve 118 canregulate, and direct, and/or control the flow of fluid by opening,closing, and/or partially obstructing passageways connected to the firstvalve 118. The first valve 118 can include a body and a bonnet thattogether form a casing that hold the fluid that passes through the firstvalve 118. The first valve 118 can comprise any desired valve type suchas, for example, a ball valve, a choke valve, a check valve, a gatevalve, a glow valve, or a needle valve.

In one embodiment, the valve 118 can be formed as a portion of a Y-piece120 including, which can be a Y-strainer. As seen in FIG. 1, the Y-piece120 can include a drain 122 located at one of the ends of the Y-piece120. In some embodiments, for example, the drain 122 can comprise adrain valve. The drain valve can allow fluid to be drained from theY-piece 120. In some embodiments, for example, the drain valve can besealed so as to prevent fluid from draining from and to prevent fluidfrom entering into the Y-piece 120.

As also seen in FIG. 1, the Y-piece 120 can comprise one or severalports 124. In some embodiments, for example, the ports 124 can be sealedto prevent fluid from draining from and/or from entering into theY-piece 120, In some embodiments, for example, the one or several ports124 can be sealed with the corresponding number of plugs. In someembodiments, one or several of these plugs can be removed from one orseveral of the ports 124 to allow placement of instrumentation so as toaccess the contents of the Y-piece 120. In some embodiments, forexample, this instrumentation can measure the pressure, temperature, orflow rate, of the fluid passing through the Y-piece 120. In one specificembodiment, the ports 124 can include a pressure and temperature (PT)port connected to instrumentation configured to measure the pressure andtemperature of the fluid within the Y-piece 120.

The Y-piece 120, and the first control section 102, connect to thesecond piping section 108 via the second union 126. As seen in FIG. 1,one portion of the second union 126 connects to the Y-piece 120 of thefirst control unit 102, and the second portion of the second union 126connects to the second piping section 108.

As further seen in FIG. 1, the second end of the second piping section108 connects to the second control section 104 via a third union 128. Insome embodiments, a portion of the third union 128 connects to thesecond end of the second piping section 108 and another portion of thethird union 128 connects to the second control section 104.

The second control section 104 comprises a variety of components, asseen in FIG. 1, the second control section 104 includes a first pressureand temperature (PT) port 130. Like the PT port discussed above, thefirst PT port 130 can allow instrumentation to access the fluidcontained within and/or passing through the second control section 104to determine the pressure and/or temperature of that fluid In someembodiments, for example, the first PT port can be sealed and/orsealable.

As seen in FIG. 1, the second control section 104 can further include,for example, a pressure gauge 132. In some embodiments, the pressuregauge can provide a visual indication of the pressure within the secondcontrol section 104 and/or within the piping stick 100. In someembodiments, the pressure gauge 132 can comprise a digital and/or analogpressure gauge, and can provide pressure readings over any desiredpressure range and to any desired level of accuracy. In someembodiments, for example, the pressure range and level of accuracyprovided by the pressure gauge 132 can correspond to the specificapplication for which the piping stick 100 is being used.

The second control section 104 can further include a control valve 134such as, for example, an ATC control valve. In some embodiments, forexample, the control valve 134 can comprise a two and or three way ATCcontrol valve. The ATC control valve may either be of a type thatprovides only on-off control, or be of a type that provides proportionalcontrol. An electrical signal can be supplied to the ATC control valvefrom a controller such as, for example, a DDC controller, via a controlsignal cable and can energize and control the operation of the ATCcontrol valve. In some embodiments, and as seen in FIG. 1, the controlvalve 134 can be connected to the second control section 104 via atailpiece 136.

The second control section 104 can, in some embodiments, include asecond pressure and temperature (PT) port 138. The second PT port 138can allow instrumentation to access the fluid contained within and/orpassing through the second control section 104 to determine the pressureand/or temperature of that fluid. In some embodiments, for example, thesecond PT port can be sealed and or sealable.

The second control section 104 can, in some embodiments, include asecond valve 140 which can be, for example, a manual balancing valve.The manual balancing valve can be provided with various features, suchas manually adjustable stems for valve port opening or a combination ofa venturi or orifice and an adjustable valve; a stem indicator and/orscale to indicate the relative amount of valve opening, pressure taps toprovide readout of the pressure difference across the valve port or theventure/orifice, the capability to be used as a shutoff for futureservice of the heat transfer terminal, a locking device for fieldsetting the maximum opening of a valve, or a body tapped for attachingdrain hose.

Balancing valves, including automatic type (pressure independent) andmanual balancing valves are supplied by a water side salesrepresentative and sold directly to the Piping Contractor. There areseveral manufacturers of balancing valves such as Griswold, Flow design,Nexus, and the like. Isolation valves, drains, air vents and otherancillary piping components are supplied by a water side salesrepresentative and sold directly to the Piping Contractor. There areseveral manufacturers of these types of products such as Nibco, Gerhard,and the like.

Manual balancing valves can be, for example, field adjusted by waterbalancing technicians, Automatic/pressure independent balancing valvescan maintain the specified GPM regardless of the pressure drop acrossthe coil. Some manual balancing valves are referred to as “circuitsetters” which are a type of balancing valve that involves manualbalancing. When balancing a system, once a valve is set and the nextvalve is set, the preceding valve(s) are revisited to adjust thesettings again. This is due to the fact that a manual valve involves anadjustable orifice, not a flow controller. Once pressure changes in thesystem after the initial setting, the flow rate also changes. Suchdevices typically limit flow when the system is operating at the exactsame level as when it was originally set up, In most systems this flowcondition typically does not occur because of variable speed pumps anddrives. Static, dynamic, and automatic balancing (e.g. Total Authority)valves often require at least 50% less cost in balancing/commissioningas the manual valve. Once set, they may be set forever if no changeshave to be made to the flow, and system, These types of valves allow for20 to 30% fewer balancing valves on a project thus reducing staticpressure in the system as a whole. Energy consumption over the manualsystem may be considerable and a consideration in applying these valves.Generally speaking, a 20% savings can be claimed with static and dynamicand potentially larger savings with Total Authority Valves.

As depicted in FIG. 1, the second valve 140 can be attached to and/orintegrally formed in Y-piece 142 which can be, for example, aY-strainer. The Y-piece 142 can connect to the first end of the thirdpiping section 110 via a fourth union 144. A portion of the fourth union144 can connect to the Y-piece 142 and another portion of the union 144can connect to the first end of the third piping section 110.

In some embodiments, for example, the piping stick 100 can include oneor several flow direction indicators 146. In some embodiments, the flowdirection indicators 146 can include a first set of flow directionindicators 146 associated with the first control section 102 and thesecond set of flow direction indicators 146 associated with the secondcontrol section 104, In some embodiments, for example, the flowdirection indicators 146 associated with the first and/or second controlsections 102, 104 can indicate the direction of fluid flow through thefirst and/or second control sections 102, 104 when the first and/orsecond control sections 102, 104 are installed into a zone-control unit.Thus, the flow direction indicators 146 can facilitate the properattachment of the first and/or second control sections 101, 104 to thezone-control unit.

In some embodiments, for example, the flow direction indicators 146 canbe specific to the control section 102, 104 with which they areassociated. Thus, for example, in some embodiments the flow directionindicators 146 associated with the first control section 102 can includefeatures distinguishing them from flow direction indicators 146associated with the second control section 104. These distinguishingfeatures can be any feature capable of allowing differentiation betweenthe first control section 102 and the second control section 104. Insome embodiments, these features can include, for example, a humanand/or computer readable code, pattern, indicia, and/or text-string.

These distinguishing features can include, for example, an indicator ofthe function of the control section 102, 104, and/or an indicator of thetype of fluid traveling through the control section 102, 104. In someembodiments, for example, the flow direction indicators 146 can includeone or several characters indicating the function of the control section102, 104 and/or the type of fluid traveling through the control section102, 104 such as, for example, indicating that the first control section102 is an inlet and/or indicating that the second control section 104 isan outlet and/or indicating that the fluid passing through the firstcontrol section 102 is supply fluid and/or indicating that the fluidpassing, Through the second control section 104 is return fluid.

In one embodiment for example, the flow direction indicators 146 caninclude coloration and/or a color scheme to indicate the function of thecontrol section 102, 104 and/or to indicate the type of fluid traveling:through the control section 102″ 104 with which the flow directionindicators 146 are associated. In one embodiment, for example, the flowdirection indicator 146 associated with the first control section 102can comprise a first color and the flow direction indicator 146associated with the second control section 104 can comprise a secondcolor. In Some embodiments, for example, the first color can bedifferent from the second color. In one embodiment, for example, the nowdirection indicators 146 associated with the first, control section 102can include red features such as, for example, one or several redcharacters, and the flow direction indicators 146 associated with thesecond control section 104 can include 15 black features such as, forexample, one or several black characters.

The flow direction indicators 146 can comprise any feature configured toindicate the desired direction of fluid flow through the first and/orsecond control sections 102, 104, In one embodiment, for example, theflow direction indicators 146 can be formed into the first and/or secondcontrol sections 102, 104 and/or the first, second, and/or third pipingsections 106, 108, 110. In one embodiment for example, the flowdirection indicators 146 can be attached to the first and/or secondcontrol sections 102, 104 and/or the first, second, and/or third pipingsections 106, 108, 110 and can be, for example, adhered to one orseveral of those components 102, 104, 106, 108, 110. In one specificembodiment, for example, the flow direction indicators 146 can includean indicator of the desired fluid flow direction such as, for example,an arrow, and/or an indicator of a property of the fluid or the type offluid desired to flow through the first and/or second control sections102, 104.

In some embodiments, for example, the piping stick 100 can comprise oneor several cutting indicators. In some embodiments, cutting indicatorscan indicate how assembly portions can be created from the piping stick100. Specifically, in some embodiments, the cutting indicators canindicate where a cut should be made on one of the piping sections 106,108, 110 to separate the piping stick 100 into assembly portions. In oneembodiment, for example, the cutting indicators can be formed into thefirst and/or second control sections 102, 104 and/or the first, second,and/or third piping sections 106, 108, 110. In one embodiment, forexample, the cutting indicators can be attached to the first and/orsecond control sections 102, 104 and/or the first, second, and/or thirdpiping sections 106, 108, 110 and can be, for example, adhered to one orseveral of those components 102, 104, 106, 108, 110, In one specificembodiment, for example, the cutting indicators can include an indicatorof the desired location for a cut such as, for example, an arrow.

As depicted in FIG. 1, the piping stick 100 includes a plurality offirst cutting indicators 148 and a plurality of second cuttingindicators 150. As depicted in FIG. 1, the plurality of first cutindicators 148 indicates a direction in which a cut is desired to beplaced, which direction is indicated by a first arrow, and the pluralityof second cutting indicators 150 indicates a second direction in which acut is desired to be placed, which direction is indicated by a secondarrow. As further seen in FIG. 1, the first cutting indicators 148 arepaired with the second cutting indicators 150 such that the cuttingindicators 148, 150 define a region in, which each cut can be placed.

The perspective view of FIG. 1 A illustrates one embodiment of a pipingstick assembly 100-A. In contrast to the piping stick 100 depicted inFIG. 1, the piping stick assembly 100-A comprises a two-piece pipingstick assembly 100-A. Specifically, the piping stick assembly 100-Aincludes a first stick portion of 170 and the second stick portion 172.Both the first stick portion 170 and the second stick portion 172include one of the control sections 102, 104, and piping sections 174,176, 178, 180 connected to the one of the control section 102, 104.

The first stick portion 170 of the piping stick assembly 100-A includesa first piping section 174. The first piping section 174 includes afirst cap 112 at a first end and is connected to the first controlsection 102 at a second end. The first stick portion 170 of the pipingstick assembly 100-A also includes a second piping section 176. Thesecond piping section 176 includes second cap 114 at a first end and isconnected to the first control section 102 at a second end. The pipingsections 174, 176 can include the features and properties of the pipingsections 106, 108, 110 discussed above.

The second stick portion 172 of the piping stick assembly 100-A includesa third piping section 178. The third piping section 178 includes afirst cap 112 at a first end and is connected to the second controlsection 104 at a second end. The second stick portion 172 of the pipingstick assembly 100-A also includes a fourth piping section 180. Thefourth piping section 180 includes second cap 114 at a first end and isconnected to the second control section 104 at a second end. The pipingsections 178, 180 can include the features and properties of the pipingsections 106, 108, 110 discussed above.

In some embodiments, for example, the first stick portion 170 and thesecond stick portion 172 can be inserted into and/or stored in handles252. The details of the handles 252 will be discussed at greater lengthbelow with reference to FIGS. 2, 3, and 4A, Further details regardingthe handles 252, also referred to as brackets, and alternate embodimentsof the handles are found in U.S. Pat. No. 6,951,324, filed Sep. 17,2003, the entirety of which is hereby incorporated by reference herein.

The piping stick 100 can be provided to the contractor separate fromand/or with a zone-control unit FIGS. 2 and 3 depict embodiments of thezone-control unit adapted for receiving the piping stick 100 so that thepiping stick 100 can be provided to the contractor with the zone-controlunit.

The perspective view of FIG. 2 illustrates a fully-functionalzone-control unit referred to by the general reference character 200,also referred to herein as an HVAC terminal unit. Further detailsrelating to the zone-control unit 200 can be found in U.S. patentapplication Ser. No. 11/972,479, filed Jan. 10, 2008, and published asU.S. Publication No, 2008/0164006, published on Jul. 10, 2008, theentirety of which is hereby incorporated by reference herein.

The fully-functional zone-control unit 200 depicted in FIG. 2, whichillustrates one embodiment of the present invention, preferably includesa mechanical terminal unit 202 having a casing 204. The casing 204,which can be made from various materials of differing thicknesses, isfrequently made from galvanized sheet steel material. Frequently, thecasing 204 is lined with a thermal insulation material, not visible inFIG. 2, which may be chosen from various different types such asfiberglass insulation, rigid duct board fiber insulation, polyolefin,closed cell foam insulation, etc, In some embodiments, insulationcontained in zone-control unit 200 complies with an industry standard,such as a standard set by the Office of Statewide Health and PlanningDepartment (OSHPOD).

For VAV zone-control units 200, the mechanical terminal unit 202preferably includes a damper assembly, not visible in FIG. 2. The damperassembly is supported for rotation within the casing 204 by a shaftwhich extends through and beyond the casing 204. The mechanical terminalunit 202 of a zone-control unit 200 that includes the damper assemblyalso includes a DDC controller (not shown) that is coupled to a dampermotor, (not shown), which rotates the damper assembly. The DDCcontroller receives a signal from a thermostat or room sensor andresponsive thereto controls operation of the damper assembly to regulatethe amount of heating or cooling provided by air leaving thezone-control unit 200. The DDC controller may be selected from variousdifferent types such as pneumatic, analog electronic or direct digitalelectronic. The mechanical terminal unit 202 also includes an airflowsensor, also not visible in FIG. 2, which can be located near an airinlet to the easing 204 and may be selected from various types forsensing the velocity of air entering the casing 204.

To heat or cool air flowing through the mechanical terminal unit 202,the casing 204 includes a coil 222 that is located near the air inletthereto, and which adapts the mechanical terminal unit 202 for inclusionin a hydronic HVAC system. The casing 204 includes both an inlet collar,not visible in FIG. 2, and an outlet connection 224, each of which isadapted to mate with a building's HVAC duct-work. If a zone-control unit200 were to be assembled at a construction site, the mechanical terminalunit 202 would arrive there with the various components listed abovemostly assembled, other than the DDC controller and the damper motor, bythe terminal unit's manufacturer.

The mechanical terminal unit 202 is preferably selected from amongvarious different types and styles sold by Krueger based in Richardson,Tex. Krueger is a division of Air Systems Components (ASC) which is partof the Dayton, Ohio Air System Components Division of TomkinsIndustries, Inc, of London, England.

To fashion the mechanical terminal unit 202 into a zone-control unit 200ready for installation into a building's HVAC system, various plumbingcomponents can be added for circulating either hot or cold water throughthe coil 222. For supplying water to the coil 222 the zone-control unit100 includes an inlet piping assembly 230. The piping assembly 230includes an L-shaped section of pipe 231 which connects at one end to alower header of the coil 222, not visible in FIG. 2.

The zone-control unit 200 also includes an outlet piping assembly 232for receiving water from the coil 222. A short length of pipe 234, whichends in a tee 236, connects to a header 238 of the coil 222. A manualair vent 242 is connected to and projects upwards above the tee 236 tofacilitate eliminating air from the piping assemblies 230, 232 followingfirst assembling the HVAC system, or reassembly of the zone-control unit100 when maintenance or repairs become necessary. An L-shaped section ofpipe 244 is connected to and descends below the tee 236. Also inaccordance with embodiments of the present invention, each pipe 231, 244is sealed by a spun copper cap 246 which can be five (5) times thickerthan the pipe 231, 244.

To reduce any possibility that a zone-control unit 200 might be damagedwhile being transported from its assembly, test and qualificationlocation to a construction site and to facilitate handling thezone-control unit 200 during its installation into the HVAC system, inaccordance with the embodiment of the present invention illustrated inFIG. 2 each zone-control unit 200 also includes a pair of handles 252that are preferably secured to the casing 204 of the mechanical terminalunit 202 near opposite ends thereof.

Each of the handles 252 includes an L-shaped handle mounting bracket 255which is rigidly secured to the mechanical terminal unit 202 on the sidenearest to the piping assemblies 230, 232, As depicted in FIG. 2, thehandle mounting brackets 255 are secured near opposite ends of thezone-control unit's casing 204. Each of the handles 252, for exampleillustrated in FIG. 2, is formed by a plate of sheet metal.

The handles 252 can include features configure to secure the pipingassemblies 230, 232 and to secure and/or support the piping stick 100.In the embodiment depicted in FIG. 2, each handle 252 is pierced by aplurality of circularly-shaped holes 254. The holes 254 each receive agrommet 256 that fits snugly around the piping assemblies 230, 232and/or the piping stick 100 where they pass through the handles 252. Inthe embodiment, depicted in FIG. 3, the handles 252 can include acut-out 300 that is sized and shaped to receive the piping stick 100.The cut-outs 300 can comprise a variety of shapes, including, forexample, C-shaped, L-shaped, or any other desired shape. The cut-outs300 can be lined with the cushioning material 304 that can fit snuglyaround the piping stick 100 where it contacts the handles 252. In someembodiments, and as depicted in FIG. 3, the handles 252 can include oneor more securement features 304. The securement features 304 can beconfigured to allow the securing of the piping stick 100 to the handles252. In some embodiments, for example, the securement features cancomprise one or several holes located on opposite sides of the cutouts300 to thereby allow the use of a tie such as, for example, a wireand/or string to secure the piping stick 100 to the handles 252.

Arranged in this way, the handles 252 provide a structure formechanically coupling the mechanical terminal unit 202 and the pipingassemblies 230, 232 together thereby reducing any possibility that thezone-control unit 200 might be damaged while being transported from itsassembly, test and qualification location to a construction site.Furthermore, the handles 252 protect zone-control units 200 duringshipping, and facilitate their handling during installation into theHVAC system such as maneuvering zone-control units 200 into position ina building's ductwork. During installation, the handles 252 maintainpositional relation-ships between the mechanical terminal unit 202including the coil 222 and the piping assemblies 230, 232 because thehandles 252 mechanically bind the entire zone-control unit 200 togetherinto a single unit.

FIG. 4 depicts a schematic: illustration of one embodiment of assemblyportions created from a piping slick 100. As seen in FIG. 4, the pipingstick 100 has been converted to a first assembly portion 400, a secondassembly portion 402, third assembly portion 404, and a fourth assemblyportion 406. The assembly portions can include portions of the pipingstick 100 attachable to the zone-control unit 200, and specifically tothe piping assemblies 230,232 of the zone-control unit 200, and portionsthe piping stick 100 that are not attachable to the zone-control unit100.

As seen in FIG. 4, the first assembly portion 400 comprises a firstportion 106-A of the first piping section 106 and the first cap 112. Inthe embodiment depicted in FIG. 4, the first assembly portion 400 is notattachable to the zone-control unit 200.

As seen in FIG. 4, the second assembly portion 402 comprises a secondportion 106-B of the first piping section 106, the first control section102, and a first portion 108-A of the second piping section 108. In theembodiment depicted in FIG. 4, the second assembly portion 402 isattachable to inlet piping assembly 230, and specifically, the secondportion 106-B of the first piping section 106 is attachable to a portionof the inlet piping assembly 230 that is exposed by the removal of spuncopper cap 246.

As seen in FIG. 4, the third assembly portion 404 comprises a secondportion 108-B of the second piping section 108, the second controlsection 104, and a first portion 110-A of the third piping section 110.In the embodiment depicted in FIG. 4, the third assembly portion 404 isattachable to outlet piping assembly 232, and specifically, the secondportion 108-B of the second piping section 108 is attachable to aportion of the outlet piping assembly 232 that is exposed by the removalof spun copper cap 246.

As seen in FIG. 4, the fourth assembly portion 406 comprises a secondportion 110-B of the third piping section 110 and the second cap 114. Inthe embodiment depicted in FIG. 4, the fourth assembly portion 406 isnot attachable to the zone-control unit 200.

FIG. 4A is a perspective view of a fully-functional zone-control unit200 includes a casing 204 from which a pair of handles 252 project, andthe second and third assembly portions 402, 404 that include controlsections 102, 104. As depicted in FIG. 4A, the second and third assemblyportions 402, 404 are connected to inlet and outlet piping assemblies230, 232. Specifically, the second assembly portion 402 is connected topipe 231 of the inlet piping assembly 230, and the third assemblyportion 404 is connected to pipe 244 of the outlet piping assembly 232.In some embodiments, for example, the assembly portions 402, 404 can beconnected to the inlet and outlet piping assemblies 230, 232 in anydesired fashion. In some embodiments, this connection can be made, forexample, with a union, by mechanically connecting the pieces together,by adding the pieces together, by soldering the pieces together, bybrazing the pieces together, and/or adhering the pieces together.

In some embodiments, for example, the unconnected end of the assemblyportions 402, 404, the end that is not connected to the pipingassemblies 230, 232 can be connected to other portions of an HVACsystem. In some embodiments, for example, this can include connectingthe unconnected end of the assembly portions 402, 404 to return and/orsupply piping. In some embodiments, the return and/or supply piping cantransport fluid to and from the assembly portions 402, 404 and thezone-control unit 200. In some embodiments, for example, thesemi˜portions 402, 404 can be connected to other portions of the HVACsystem in any desired fashion.

In some embodiments, this connection can be made, for example, with aunion, by mechanically connecting the pieces together, by welding thepieces together, by soldering the pieces together, by brazing the piecestogether, and/or adhering the pieces together.

In some embodiments, for example, the assembly portions 402, 404 caninteract with the handles 252 via the piping assemblies 230, 232 and/orthe other portions of the HVAC system which can be, for example, extendthrough holes 254 of the handles 252, and specifically extend throughthe grommet 256 located in the holes 254 of the handle 252. In someembodiments, for example, portions of the assembly portions 402, 404 canextend through the holes 254 of the handles 252, and specifically extendthrough the grommet 256 located in the holes 254 of the handles 250 tothereby connect the assembly portions 402, 404 with the handles 252. Theinteraction of the assembly portions 402, 404 with the handles 252 cansecure the assembly portions 402,404 relative to the zone-control unit200.

FIG. 5 is a flowchart illustrating one embodiment of a process 500 forcreating a piping stick 100. In some embodiments, the process 500 can beperformed at the site of the assembly of the HVAC system and in someembodiments, the process 500 can be performed at a site remote from theassembly of the HVAC system such as, for example, in a factory.

The process 500 begins at block 502 wherein the piping stick 100 isassembled. Assembling the piping stick 100 can include the collection ofthe components to be used in the piping stick 100 and the connection ofthe components to be used in the piping stick 100.

After the piping stick 100 has been assembled, the process 500 proceedsto block 504 wherein the piping stick 100 is pressurized. In someembodiments, for example, the piping stick 100 can be pressurized byincreasing the pressure within the piping stick 100 and/or by decreasingthe pressure within the piping stick 100. Thus, in some embodiments, thepressure within the piping stick 100 is less than and/or greater thanambient pressures. In some embodiments, for example, the pressure withinthe piping stick 100 can be changed by reusing fluid from the pipingstick 100 and or by adding fluid to the piping stick 100.

After the piping stick has been pressurized, the process 500 proceeds toblock 506 wherein the piping stick 100 is validated. In someembodiments, for example, validation the piping stick 100 can includedetermining whether the piping stick 100 is sealed and/or whether thepiping stick 100 has leaks. After the piping stick 100 has beenvalidated, the process 500 can terminate.

FIG. 6 is a flowchart illustrating one embodiment of a process 600 thatcan be used to assemble the piping stick 100. In some embodiments, forexample, the process 600 can be performed as a portion of the assemblingof the piping stick 100 described in block 502 of FIG. 5. The process600 begins at block 602 wherein the first control section 102 isassembled. In some embodiments, for example, the assembly of the firstcontrol section 102 can include the collection the components of thefirst control section 102 and the connection of the components of thefirst control section 102. In some embodiments, for example, thecomponents of the first control section 102 can be connected to adesired fashion including, for example, screwed and or threadedtogether, adhere to, brazed, or soldered.

After the first control section 102 is assembled, the process 600proceeds to block 604 wherein the first piping section 106 is attached.In some embodiments, for example, the first piping section 106 isattached to the first control section 102. As discussed above, in someembodiments, the first piping section 106 can be attached to the firstcontrol section 102 via a union.

After the first piping section 106 is attached, the process proceeds toblock 606 wherein the second piping section 108 is attached. In someembodiments, for example, the second piping section 108 is attached tothe first control section 102. As discussed above, in some embodiments,the first end of the second piping section 108 can be attached to thefirst control section 102 via a union.

After the second piping section 108 is attached, the process 600proceeds to block 608 wherein the second control section 104 isassembled. In some embodiments, for example, the assembly of the secondcontrol section 104 can include the collection the components of secondcontrol section 104 and the connection of the components of the secondcontrol section 104. In some embodiments, for example, the components ofthe second control section 104 can be connected in a desired fashionincluding, for example, screwed and or threaded together, adhered,brazed, or soldered.

After the second control section 104 is assembled, the process 600proceeds to block 610 wherein the second control section 104 is attachedto the second piping section 108. In some embodiments, for example, thesecond control section 104 is attached to the second piping section 108.As discussed above, in some embodiments, the second end of the secondpiping section 108 can be attached to the first control section 102 viaa union.

After the second control section 104 is attached, the process 600proceeds to block 612 wherein the third piping section 110 is attachedto the second control section 104. In some embodiments, for example, thethird piping section 110 is attached to the second control section 104.As discussed above, in some embodiments, the third piping section 110can be attached to the second control section 104 via a union. After thethird piping section is attached, the process 600 proceeds to block, 614and then proceeds to block 504 of FIG. 5.

FIG. 7 is a flowchart illustrating one embodiment of a process 700 thatcan be used to pressurize the piping stick 100. In some embodiments,for, example, the process 700 can be performed as a portion of thepressurizing the piping stick 100 described in block 504 of FIG. 5. Theprocess 700 begins in block 702 wherein the first piping section 106 issealed. In some embodiments, for example the sealing of the first pipingsection 106 can include the creation of the first cap 112 to seal thesecond end of the first piping section 106.

After the first piping section 106 has been sealed, the process 700proceeds to block 704 wherein the third piping section is sealed. Insome embodiments, for example the sealing of the third piping section110 can include the creation of the second cap 114 to seal the secondend of the third piping section 110.

After the third piping section 110 has been sealed, the process 700proceeds to block 706 wherein a pressure change within the piping stick100 is affected. In some embodiments, for example, the pressure withinthe piping stick can be changed by increasing the pressure within thepiping stick 100 to a pressure greater than ambient pressure ordecreasing the pressure within the piping stick 100 to a pressure lessthan ambient pressure. In some embodiments, for example the pressurewithin the piping stick 100 can be increased to a pressure greater thanthe ambient pressure by adding fluid into the piping stick 100, and insome embodiments, for example, the pressure within the piping stick 100can be decreased to a pressure less than the ambient pressure byremoving fluid from of the piping stick 100. In some embodiments, apressure change can be affected within the piping stick 100 so that thepiping stick 100 attains a desired self-point pressure.

After a pressure change in the piping slick has been affected, theprocess 700 proceeds to decision state 708 wherein it is determined ifthe pressure the piping stick 100 is proper. In some embodiments, thisdetermination can include measuring the pressure within the piping stickand comparing the pressure to the desired set-point pressure of thepiping stick 100. If it is determined that the pressure the piping stick100 is improper, the process 700 returns to block 706. If it isdetermined that the pressure within the piping stick 100 is proper, thenthe process 700 proceeds to block 710 and to block 506 of FIG. 5.

FIG. 8 is a flowchart illustrating one embodiment of a process 800 forvalidating a piping stick 100. In some embodiments, for example, theprocess 800 can be performed as a portion of the validating of thepiping stick 100 described in block 506 of FIG. 5. The process 800begins at block 802 wherein the pressure within the piping stick 100 ismeasured. In some embodiments, for example, the pressure within thepiping stick 100 can be measured by the pressure sensor accessingportion the piping stick 100 through, for example, one of the ports ofthe piping stick 100.

After the pressure the piping stick 100 has been measured, the process800 proceeds to decision state 804 wherein it is determined if themeasured pressure is correct. In some embodiments, for example, thedetermination of whether the measured pressure is correct can includecomparing the measured pressure within the piping stick 100 to thedesired set-point pressure of the piping stick 100.

If it is determined that the measured pressure within the piping stick100 is correct, the process proceeds to block 806 wherein the pipingstick 100 is indicated as compliant. In some embodiments, for example,the indication of the complaint piping stick 100 can comprise anindication that the piping stick 100 does not have any leaks. After thepiping stick 100 is indicated as compliant, the process 800 canterminate.

Returning again to decision state 804, if it is determined that thepressure within the piping stick 100 is incorrect, the process 800proceeds to block 808 wherein leaks within the piping stick 100 areidentified. In some embodiments, for example, the identification of theleaks can include testing of each of the joints of the piping stick 100to identify the location of the leak. In some embodiments, for exampleidentifying the location of any of the leaks can include dividing thepressurized volume of the piping stick 100 into a plurality of smallerpressurized volumes and determining whether the smaller pressurizedvolumes are losing pressure, which pressure loss provides an indicationof a leak within the smaller pressurized volume.

After any leaks in the piping stick 100 have been identified, theprocess 800 proceeds to block 810 wherein the piping stick 100 issealed. In some embodiments, for example, the sealing of the pipingstick 100 can include the sealing of the leaks identified in block 808.After the identified leaks are sealed, the process 800 proceeds to block812 and returns to block 706 of FIG. 7.

FIG. 9 is a flowchart illustrating one embodiment of a process 900 forassembling an HVAC unit and/or a zone-control unit. The process 900 canbe perfumed by, for example, the contractor. The process begins at block902 wherein the piping stick is verified. In some embodiments, forexample the verification the piping stick can include ascertainingwhether the piping stick is a functional and specified condition. Afterthe piping stick has been verified, the process 900 proceeds to block904 wherein assembly portions are created. In some embodiments, forexample, the assembly portions can be created from the piping stick 100.After the assembly portions arc created, the process 900 proceeds toblock 906 wherein the HVAC unit is assembled, after which, the process900 can terminate.

FIG. 10 is a flowchart illustrating one embodiment of a process 1000 forverifying the piping stick 100. In some embodiments, for example, theprocess 1000 can be performed as a portion of the verifying of thepiping stick 100 described in block 902 of FIG. 9. The process begins atblock 1002, wherein the piping stick 100 is obtained. In someembodiments, for example, the piping stick 100 can be obtained from asupplier of piping sticks 100 such as, for example, a manufacturer, adistributor, a retailer, and/or a service provider. In some embodiments,the piping stick 100 can include information relating to features of thepiping stick 100 such as, for example, the set-point pressure of thepiping stick 100.

After the piping stick 100 has been obtained, the process 1000 proceedsto block 1004 wherein the piping stick pressure is measured. In someembodiments, for example, the piping stick pressure can be measured by apressure sensor accessing the interior volume of the piping stick 100via one of the ports of the piping stick 100. In one embodiment, forexample, the pressure of the piping slick 100 can be measured by, forexample, the pressure gauge 132.

After the pressure the piping stick has been measured, the processproceeds to decision state 1004 wherein it is determined if the pressurethe piping stick is acceptable. In some embodiments, for example, thedetermination of whether the pressure the piping stick too is acceptablecan be made by comparing the measured pressure of piping stick 102 tothe set-point pressure of the piping stick 100, In some embodiments, forexample, the set point pressure the piping stick 100 can include thepressure to which the piping stick 100 was set, as, well as the range ofacceptable pressures of the piping stick 100.

If the measured pressure of the piping stick 100 is unacceptable, thenthe process 1000 proceeds to block 1008 wherein the piping stick isrejected. In some embodiments, for example, the rejection of pipingstick 100 can include the addition of an indicator of the failure of thepiping stick 100 to have a pressure within the acceptable pressurerange. After the piping stick 100 has been rejected, the process 1000returns to block 1002.

Returning again to decision state 1004, if it is determined that thepressure of the piping stick 100 is acceptable, the process 1000proceeds to block 1010 wherein the piping stick 100 is accepted. In someembodiments, for example, the acceptance of the piping stick 100 caninclude the addition of an indicator of the piping stick 100 meeting theacceptable pressure ranges. After the piping stick 100 has beenaccepted, the process 1000 proceeds to block 1012 and proceeds withblock 904 of FIG. 9.

FIG. 11 is a flowchart illustrating one embodiment of a process 1100 forcreating assembly portions. In some embodiments, for example, theprocess 1100 can be performed as a portion of creating assembly portionsdescribed in block 904 of FIG. 9. The process 1100 begins at block 1102where in a first assembly portion is created. In some embodiments, forexample, the first assembly portion can correspond to one of theassembly portions 400,402,404,406 that is attachable to one of thepiping assemblies 230,232. Specifically, in one embodiment, the firstassembly portion can be one of the second assembly portion 402 and/orthe third assembly portion 404. The first assembly portion can becreated using any desired technique. In some embodiments, for example,the first assembly portion can be created by separating the firstassembly portion from the other components of the piping stick 100.

After the first assembly portion has been created, the process 1100proceeds to block 1104 wherein the second assembly portions created. Insome embodiments, for example, the second assembly portion cancorrespond to one of the assembly portions 400, 402, 404, 406 that isattachable to one of the piping assemblies 230,232. Specifically, in oneembodiment, the second assembly portion can be one of the secondassembly portion 402 and/or the third assembly portion 404. The secondassembly portion can be created using any desired technique. In someembodiments, for example, the second assembly portion can be created byseparating the second assembly portion from the other components of thepiping stick 100. After the second assembly portion is created, theprocess 1100 proceeds to block 1106 and to block 906 of FIG. 9.

FIG. 12 is a flowchart illustrating another embodiment of a process 1200for creating assembly portions. In some embodiments, for example, theprocess 1200 can be performed as a portion of the creating assemblyportions described in block 904 of FIG. 9. The process 1200 begins atblock 1202 wherein the first cap 112 is cut off of the first pipingsection 106. In some embodiments, for example, the first cap 112 can becut off of the first piping section 106 using, for example, a pipecutler, a saw, tin-snips, a shear, a torch, or any other cutting tool.In some embodiments, for example, the first cap 112 can be cut off ofthe first piping section 106 by cutting the first piping section 106between the first end and the second end of the first piping section106. In some embodiments, for example, the cutting off of the first cap112 from the other portions of the first piping section 106 can createthe first assembly portion 400.

After the first cap 112 has been cut off of the first piping section106, the process 1200 proceeds to block 1204 wherein the second cap 114is cut off of the third piping section 110. In some embodiments, forexample; the second cap 114 can be cut off of the third piping section110 using, for example, a pipe cutter, a saw, tin-snips, a shear, atorch, or any other cutting tool. In some embodiments, for example, thesecond cap 114 can be cut off of the third piping section 110 by cuttingthe third piping section 110 between the first end and the second end ofthe third piping section 110. In some embodiments, for example, thecutting off of the second cap 114 from the other portions of the thirdpiping section 110 can create the fourth assembly portion 406.

After the second cap 114 has been cut off of the third piping section110, the process 1200 proceeds to block 1206 wherein the second pipingpiece 108 is cut into two pieces. In some embodiments, for example, thesecond piping section 108 can be cut into two pieces using, for example,a pipe cutter, a saw, tin-snips, a shear, a torch, or any other cuttingtool. In some embodiments, for example, the second piping section 108can be cut into two pieces by cutting the second piping section 108between its first end and second end. In some embodiments, for example,cutting the second piping section 108 into two pieces can create thesecond and third assembly portions 402, 404. After the second pipingpiece 108 is cut into two pieces, the process 1200 proceeds to block1208 and to block 906 of FIG. 9.

FIG. 13 is a flowchart illustrating one embodiment of a process 1300 forpreparing an HVAC unit and/or zone-control unit In some embodiments, forexample, the process 1300 can be performed as part of the process 900for assembling an HVAC unit and/or zone-control unit as depicted inblock 906 of FIG. 9. The process begins at block 1302 wherein an HVACunit is obtained. In some embodiments, for example, the HVAC unit caninclude a piping stick 100 as depicted in FIGS. 2 and 3. After the HVACunit is obtained, the process 1300 proceeds to block 1304 wherein thepiping assemblies 230,232 are unsealed. In some embodiments, forexample, the unsealing of the piping assemblies 230, 232 can includecutting the spun copper caps 246 off of the pipes 231, 244. This cuttingcan be performed using any that the techniques discussed above incutting the piping stick 100. After the piping assemblies are unsealed,the process 1300 proceeds to block 1306 wherein the assembly units areconnected to the unsealed pipes 231, 244. The connection of the assemblyunits to the unsealed pipes 231, 244 can be performed using any desiredtechnique including, for example, threading, screwing, adhering, gluing,welding, soldering, or brazing. After the assembly units are connectedwith the unsealed pipes 231,244, the process 1300 can terminate.

Although the present invention has been described in terms of thepresently preferred embodiment, it is to be understood that suchdisclosure is purely illustrative and is not to be interpreted aslimiting. Consequently, without departing from the spirit and scope ofthe invention, various alterations, modifications, and/or alternativeapplications of the invention will no doubt, be suggested to thoseskilled in the art after having read the preceding disclosure.Accordingly, it is intended that the following claims be interpreted asencompassing all alterations, modifications, or alternative applicationsas fall within the true spirit and scope of the invention.

The invention claimed is:
 1. A piping apparatus for a coil/thermaltransfer device comprising: a first tubular end section; a secondtubular end section; a first valve coupled with the first tubular endsection; and a second valve coupled with the second tubular end section,wherein the first tubular end section and the first valve form a firstassembly portion and the second tubular end section and the second valveform a second assembly portion that is attached to the first assemblyportion via a tubular piping section between the first assembly portionand the second assembly portion, and wherein the second assembly portionis separable from the first assembly portion at a location associatedwith the tubular piping section to facilitate attachment of the firstassembly portion to a first pipe of the coil/thermal transfer device andattachment of the second assembly portion to a second pipe of thecoil/thermal transfer device.
 2. The piping apparatus of claim 1,wherein the first tubular end section comprises a sealed end and anon-sealed end, and wherein the non-sealed end is connected to the firstvalve.
 3. The piping apparatus of claim 1, wherein the second tubularend section comprises a sealed end and a non-sealed end, and wherein thenon-sealed end is connected to the second valve.
 4. The piping apparatusof claim 1, wherein the first valve is connected to a first controlsection and the second valve is connected to a second control section,and wherein the first valve and the second valve are open.
 5. The pipingapparatus of claim 4, wherein the first control section comprises afirst single flow assembly and the second control section comprises asecond single flow assembly.
 6. The piping apparatus of claim 4, whereinthe first control section comprises a plurality of flow assemblies. 7.The piping apparatus of claim 6, wherein the plurality of flowassemblies are connected by a plurality of piping sections.
 8. Thepiping apparatus of claim 1, further comprising: a first hydronic unitconnected to the first tubular end section and a tubular interiorsection; a second hydronic unit connected to the second tubular endsection and the tubular interior section, wherein the second hydronicunit comprises a pressure gauge, and wherein the tubular interiorsection comprises non-atmospheric pressure therein.
 9. The pipingapparatus of claim 1, further comprising a cutting indicator locatedbetween the first assembly portion and the second assembly portion,wherein the first assembly portion is separable from the second assemblyportion at the cutting indicator.
 10. The piping apparatus of claim 9,wherein the cutting indicator comprises a first cut indicator thatindicates a first cut direction and a second cut indicator thatindicates a second cut direction, and wherein the first cut directionand the second cut direction define a cut region.
 11. The pipingapparatus of claim 2, further comprising: a first cutting indicatorlocated between the first assembly portion and the second assemblyportion; and a second cutting indicator located between the sealed endand the first valve, wherein the sealed end is separable from the firstvalve at the second cutting indicator.
 12. The piping apparatus of claim3, further comprising: a first cutting indicator located between thefirst assembly portion and the second assembly portion; and a secondcutting indicator located between the sealed end and the second valve,wherein the sealed end is separable from the second valve at the secondcutting indicator.
 13. The piping apparatus of claim 1, furthercomprising: a sealed and unpressurized interior lumen defined at leastin part by the first tubular end section and the second tubular endsection.
 14. The piping apparatus of claim 1, further comprising: asealed and pressurized interior lumen defined at least in part by thefirst tubular end section and the second tubular end section.
 15. Thepiping apparatus of claim 14, further comprising a pressure gauge influid communication with the interior lumen.
 16. The piping apparatus ofclaim 14, wherein the interior lumen comprises non-atmospheric pressure.17. The piping apparatus of claim 1, wherein a first end of the firsttubular end section is sealed.
 18. The piping apparatus of claim 1,wherein a first end of the first tubular end section is unsealed. 19.The piping apparatus of claim 1, wherein a first end of the secondtubular end section is sealed.
 20. The piping apparatus of claim 1,wherein a first end of the second tubular end section is unsealed.